Installation and Operation Manual

General Installation and Operating Notes and Warnings

This Equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D (Class I, Zone 2, Group IIC) or non-hazardous locations.

This equipment is suitable for use in European Zone 2, Group II environments per compliance with EN60079-15, Electrical apparatus for explosive atmospheres – Type of protection ‘n’

These listings are limited only to those units bearing the certification identification.

Field wiring must be stranded copper wire rated at least 75 °C for operating ambient temperatures expected to exceed 50 °C.

Peripheral equipment must be suitable for the location in which it is used.

Wiring must be in accordance with North American Class I, Division 2 or European Zone 2 wiring methods as applicable, and in accordance with the authority having jurisdiction.

General Description

General

The 505E is a 32-bit microprocessor-based control designed to control single extraction, extraction/admission, or admission steam turbines. The 505E is field programmable which allows a single design to be used in many different control applications and reduces both cost and delivery time. It uses menu driven software to instruct site engineers on programming the control to a specific generator or mechanical drive application. The 505E can be configured to operate as a stand-alone unit or in conjunction with a plant’s Distributed Control System.

Operator Control Panel

The 505E is a field configurable steam turbine control and operator control panel (OCP) integrated into one package. A comprehensive operator control panel, including a two- line (24 characters each) display, and a set of 30 keys is located on the 505E’s front panel. This OCP is used to configure the 505E, make On Line program adjustments, and operate the turbine/system. Easy to follow instructions are presented in English through the OCP’s two-line display and operators can view actual and setpoint values from the same screen.

Turbine Control Parameters

The 505E interfaces with two control valves (HP & LP) to control two parameters and limit an additional parameter, if desired. These two controlled parameters are typically speed (or load) and extraction/admission pressure (or flow), however, the 505E could be utilized to control or limit: turbine inlet pressure or flow, exhaust (back) pressure or flow, first stage pressure, generator power output, plant import and/or export levels, compressor inlet or discharge pressure or flow, unit/plant frequency, process temperature, or any other turbine related process parameter. Refer to Volume 2 for details on applications.

Communications

The 505E can communicate directly with plant Distributed Control Systems and/or CRT based operator control panels, through two Modbus® * communication ports. These ports support RS-232, RS-422, or RS-485 communications using ASCII or RTU MODBUS transmission protocols. Communications between the 505E and a plant DCS can also be performed through hardwired connections. Since all 505E PID setpoints can be controlled through analog input signals, interface resolution and control is not sacrificed.

Additional Features

The 505E also provides the following features: First-Out Trip Indication (5 total trip inputs), Critical Speed Avoidance (2 speed bands), Auto Start Sequence (hot & cold starts), Dual Speed/Load Dynamics, Zero Speed Detection, Peak Speed Indication for Overspeed trip, and Isochronous Loadsharing between units.

Using the 505E

The 505E control has two normal operating modes, the Program Mode and the Run Mode. The Program Mode is used to select the options needed to configure the control to your specific turbine application. Once the control has been configured, the Program Mode is typically never again used, unless turbine options or operation changes. Once configured, the Run Mode is used to operate the turbine from start-up through shutdown. In Addition to the Program and Run modes, there is a Service Mode which can be used to enhance system operation while the unit is running. Refer to Volume 2 for information on the Service Mode.

505E Inputs and Outputs

Control Inputs

Two speed inputs which are jumper configurable for MPU (magnetic pickup units) inputs or proximity probes.

Six analog inputs are available. One is dedicated as the extraction/admission input. The remaining five are configurable. The sixth analog input has isolation circuitry and should be used for a self-powered signal that is not isolated.

Sixteen contact inputs are available. Four are dedicated for shutdown, reset, raise speed setpoint, and lower speed setpoint. Another two contact inputs must be dedicated for generator breaker and utility tie breaker if the control is used in a generator application. Ten additional contact inputs can be configured. If the unit is not used in a generator application, then twelve additional contact inputs can be configured.

Four function keys on the front panel of the control. F1 and F2 are dedicated to alarm and overspeed test, respectively. F3 and F4 can be used to enable or disable various functions of the control.

Control Outputs

Two actuator outputs with linearization curves for the HP and the LP valve outputs.

Six 4–20 mA outputs, for meters or other readouts.

Eight Form-C relay contact outputs, six that are configurable. The two dedicated relay outputs are for shutdown and alarm indication.

Control Communications

Two Modbus ports, to be used as control interfaces. The protocol can be either ASCII or RTU and the communications can be RS-232, RS-422, or RS-485.

One computer (PC) port to be used for program configuration storage. An overview of the 505E functions is shown in Figure 1-1. Use this block diagram to match the control features to the site-specific application required.

Control Overview

The 505E Digital Governor is designed to control extraction, extraction/ admission, or admission steam turbines. The difference between these turbines is the capability of the turbine to allow low pressure steam, which is at a lower pressure than the inlet, to enter and/or exit the turbine. An extraction turbine allows the lower pressure (extraction) steam to exit the turbine only and will have a non-return valve in the extraction header/line to prevent steam from entering the turbine. An admission turbine (also called induction) will allow excess header steam to enter the turbine through the low pressure inlet. An extraction/admission turbine will allow low pressure header steam to enter or exit the turbine depending on system pressures. A turbine with admission capability will have a stop valve or trip-and-throttle valve in the low pressure line to prevent steam from entering the turbine when the unit is tripped. The type of turbine used will depend on the system requirements and must be designed by the turbine manufacturer to perform the functions required.

The 505E has two independent control channels available, the speed/load and auxiliary controllers. The outputs of these two controllers are low-signal-selected (LSS) to provide to speed/load demand signal to the ratio/limiter. In addition to these channels, the speed/ load controller can be manipulated by another controller, the cascade controller. The cascade controller is ‘cascaded’ into the speed controller, whereby the speed controller setpoint is changed directly by the cascade controller output. The auxiliary controller can act as either a control channel or as a limiting channel. All three of these PID controllers have the option of utilizing an analog input signal to remotely position their setpoints. Additional features of the 505E include frequency control, isochronous loadsharing, critical speed avoidance, idle/rated control, and an automatic start sequence. There are two serial communications ports which can be used to monitor and control the turbine using Modbus protocol.

Extraction Turbines

The 505E control can be configured to operate single automatic extraction turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve. (The 505E can also operate the governor valve and the first extraction valve of multiple extraction turbines).

Single automatic extraction turbines have a high pressure stage and a low pressure stage, each controlled by a valve. Steam enters the turbine through the HP valve (see Figure 1-2). At the downstream end of the HP turbine stage and before the LP valve, steam can be extracted. The LP valve controls the entry of steam into the LP turbine stage, and the diverting of steam through the extraction line. As the LP valve is opened, more steam enters the LP stage and less is extracted.

In most cases, the operator of an extraction turbine needs to maintain both turbine speed/ load and extraction pressure/flow at constant levels. Changing the position of either the HP valve or the LP valve affects both turbine speed/load and extraction. If either the load on the turbine or the extraction demand changes, both the HP valve position and the LP valve position must be changed to maintain speed/load and extraction. The movement of both valves is automatically calculated by the 505E’s ratioing logic based on the turbine performance parameters to minimize valve/process interaction.

Admission Turbines

The 505E control can be configured to operate single automatic admission turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve.

Single automatic admission turbines have a high pressure stage and a low pressure stage, each controlled by a valve. Steam enters the turbine through the HP valve (see Figure 1-3) and at the downstream end of the HP turbine stage, before the LP valve. The LP valve controls the entry of steam into the LP turbine stage and through the admission line. As the LP valve is opened, more steam enters the LP stage.

In most cases, the operator of an admission turbine needs to maintain both turbine speed/ load and admission pressure/flow at constant levels. Changing the position of either the HP valve or the LP valve affects both turbine speed/load and admission. If either the load on the turbine or the admission demand changes, both the HP valve position and the LP valve position must be changed to maintain speed/load and admission.

The movement of both valves is automatically calculated by the 505E’s ratioing logic based on the turbine performance parameters to minimize valve/process interaction.

Extraction and Admission Turbines

The 505E control can be configured to operate single automatic extraction and admission turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve.

Single automatic extraction and admission turbines have a high pressure stage and a low pressure stage, each controlled by a valve. Steam enters the turbine through the HP valve (see Figure 1-2). At the downstream end of the HP turbine stage and before the LP valve, steam can either be extracted or admitted (inducted) into the LP turbine stage. The LP valve controls the entry of steam into the LP turbine stage. As the LP valve is opened, more steam enters the LP stage and less is extracted.

In most cases, the operator of an extraction turbine needs to maintain both turbine speed/ load and extraction or admission pressure/flow at constant levels. Changing the position of either the HP valve or the LP valve affects both turbine speed/load and extraction or admission. If either the load on the turbine or the extraction / admission demand changes, both the HP valve position and the LP valve position must be changed to maintain speed/ load and extraction/ admission. The movement of both valves is automatically calculated by the 505E’s ratioing logic based on the turbine performance parameters to minimize valve/process interaction.

Speed Control

The speed control receives a turbine speed signal from one or two magnetic pickups or proximity probes. The speed PID (proportional, integral, derivative) control amplifier then compares this signal to the speed setpoint to generate an output signal to the ratio/ limiter (through a low signal select bus).

505E Digital Governor

The speed control amplifier can also receive a programmable (optional) droop feedback signal to increase the stability of the turbine/governor system. This droop signal can be proportional to the controller’s output signal or to the system’s generator load (kW) signal.

The speed control’s setpoint is adjustable with raise or lower commands through the keypad on the front of the control, remote contact inputs or Modbus. The setpoint can also be directly set by entering the new setpoint from the keypad, or through either Modbus communications link. In addition, a remote speed setpoint analog input can be programmed to remotely position the speed setpoint.

Remote Speed Setpoint

One of the 4–20 mA inputs can be configured to remotely adjust the speed setpoint. Typically, a process control external to the 505E interfaces with this input to regulate the turbine’s speed or load to control a related process.

The remote speed setpoint input directly affects the 505E’s speed setpoint. The maximum rate at which the remote input signal can change the speed setpoint is programmable. When the remote setpoint is enabled, the speed setpoint will move at a much slower rate until the two settings are matched, at which time the speed setpoint will be allowed to move at the maximum rate. The remote speed function can be enabled and disabled as required from the front-panel keypad, remote contact inputs or the communication line.

Auxiliary Control

The Auxiliary control channel can be used to either control a parameter or limit a parameter. The Auxiliary PID controller can be used to control or limit unit load/power, plant import/export levels, inlet pressure, exhaust pressure, temperature or any other process directly related to turbine load.

The Auxiliary input is a 4–20 mA current signal. The Auxiliary PID control amplifier compares this input signal with a setpoint to produce a control output to the digital LSS (low-signal select) bus. The LSS bus sends the lowest signal to the ratio/limiter logic which determines HP and LP valve positions. The Auxiliary control amplifier can also receive a programmable (optional) droop feedback signal to increase system stability. This is a direct feedback using a portion of the Auxiliary control amplifier output.

The Auxiliary setpoint is adjustable with raise or lower commands through the keypad on the front of the control, through remote contact inputs or through the communication links. Also, the setpoint can be directly set by entering the new setpoint from the keypad or through Modbus. In addition, an analog input can be programmed to remotely position the Auxiliary setpoint.

Remote Aux Setpoint

One of the 4–20 mA inputs can be configured to remotely adjust the Auxiliary setpoint. The remote aux setpoint input directly affects the auxiliary setpoint. The maximum rate at which the remote input signal can change the auxiliary setpoint is programmable. When the remote setpoint is enabled, the auxiliary setpoint will move at a much slower rate until the two settings are matched at which time the setpoint will be allowed to move at the maximum rate. The remote aux function can be enabled and disabled as required from the front panel keypad, the remote contact inputs, or the communication links.

Load Sharing Input

The 505E is capable of using an analog input to accept a load sharing signal from Woodward’s Digital Synchronizer and Load Control (DSLC™). This input in conjunction with the DSLC allows the control to isochronously loadshare with any other system using a DSLC. The 505E’s internal summing junction adds this signal with the speed/load PID’s reference. In addition to loadsharing, the DSLC input to the 505E can be used to synchronize the unit to either the plant bus or to the utility.

Cascade Control

The Cascade control can be configured to control any system process, related to or affected by turbine speed or load. Typically this controller is used as a turbine inlet or exhaust pressure controller.

The Cascade control is a PID controller that compares a 4–20 mA process signal with the Cascade setpoint. The PID controller sets the speed controller setpoint until the process signal and the setpoint match. The Cascade control can also receive a programmable (optional) droop feedback signal to increase control loop stability. This is a direct feedback using a portion of the cascade control amplifier’s output.

The Cascade setpoint is adjustable with raise or lower commands through the keypad on the front of the control, the remote contact inputs, or the communication links. Also, the setpoint can be directly set by entering the new setpoint from the keypad or through either Modbus communications link. In addition, a remote cascade setpoint analog input can be programmed to remotely position the cascade setpoint.

Remote Cascade Setpoint

One of the 4–20 mA inputs can be configured to remotely adjust the Cascade setpoint. The remote cascade setpoint input directly affects the 505E’s Cascade setpoint. The maximum rate at which the remote input signal can change the Cascade setpoint is programmable and can be changed in the Run mode. When the remote setpoint is enabled, the Cascade setpoint will move at a much slower rate until the two settings are matched at which the setpoint will be allowed to move at the maximum rate. The remote cascade function can be enabled and disabled as required from the front-panel keypad, the remote contact inputs or either Modbus communication link.

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